Segment:
Cruiser Motorcycle
Target Audience:
Riders seeking a customizable, classic-styled cruiser with a performance heritage.
Key Competitors 2008:
Indian Chief, Victory Kingpin, certain models from Honda (Shadow series), Yamaha (V-Star series), and Suzuki (Boulevard series).
Model Highlight:
The XL 1200C Custom emphasizes chrome styling, a low seat height, and a rider-focused experience, offering a platform for personalization.
Manual Value Proposition:
This manual empowers owners and technicians with the knowledge to maintain, repair, and troubleshoot their 2008 Sportster 1200 Custom effectively, preserving its performance and value.
Engine:
Complete service, maintenance, and overhaul procedures for the Evolution 1200cc engine, including top-end (cylinder heads, valves, camshafts) and bottom-end (crankshaft, connecting rods, bearings) assemblies.
Fuel System:
Detailed information on the fuel injection system (EFI), throttle body, fuel pump, fuel filter, and injectors. Troubleshooting and calibration procedures.
Ignition System:
Ignition module, spark plugs, ignition coils, and related wiring. Diagnostic procedures and timing adjustments.
Transmission:
Service and repair of the 5-speed transmission, including clutch operation, gear selection mechanisms, primary drive, and final belt drive maintenance.
Chassis And Suspension:
Front fork (telescopic) service, seal replacement, oil level and type specifications. Rear shock absorber inspection and replacement. Swingarm and pivot bearing service.
Brakes:
Front and rear brake system maintenance, including brake caliper service, pad replacement, fluid flush and bleed procedures. Master cylinder and brake line inspection.
Electrical System:
Wiring diagrams for all electrical components, including lighting, starting system (starter motor, solenoid), charging system (alternator, regulator), battery, and instrumentation. Troubleshooting electrical faults.
Bodywork And Fittings:
Information on fenders, fuel tank mounting and removal, seat assembly, handlebar removal and installation, and cosmetic component service.
Maintenance:
Scheduled maintenance tasks, including oil changes, filter replacements, chain/belt adjustment, tire pressure checks, brake fluid checks, and general inspection.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, including starting problems, engine performance issues, electrical faults, and braking system anomalies.
Repair:
Step-by-step repair instructions for various components, from minor adjustments to major overhauls and component replacements.
Diagnostics:
Guidance on using diagnostic tools and interpreting fault codes (if applicable for the model year and system).
Depth Level:
Advanced diagnostics and complete rebuild procedures. Suitable for professional technicians and experienced DIY enthusiasts.
Digital Format:
PDF (Portable Document Format) - allowing for searchability, zooming, and printing of specific pages.
Image Resolution:
High-resolution images and diagrams for clarity.
Digital Access:
Downloadable file for offline access.
Digital Content:
Content is presented as digital pages, potentially mimicking a printed manual's layout.
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
1202 cc (73.35 cubic inches)
Bore X Stroke:
3.50 in x 3.81 in (88.9 mm x 96.8 mm)
Valve Train:
Overhead valves (OHV), 2 valves per cylinder
Cooling System:
Air-cooled
Claimed Horsepower:
Approximately 65-70 HP (specific figure can vary by source and testing)
Claimed Torque:
Approximately 70-75 ft-lbs @ 3500 RPM (specific figure can vary by source and testing)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane (AKI)
Oil Capacity W Filter Change:
3.0 US qt (2.8 L)
Oil Type Recommendation:
Harley-Davidson SYN3 Synthetic 20W50 or equivalent API SG or higher, JASO FD certified motorcycle oil.
Transmission Type:
5-speed constant mesh
Primary Drive:
Duplex chain, 34/46 ratio
Final Drive:
Belt, 32/65 ratio
Clutch:
Wet, multi-plate, compensated
Transmission Fluid Type:
Harley-Davidson Formula+ Transmission Oil (or equivalent SAE 50 gear oil for primary drive and transmission)
Transmission Fluid Capacity:
25-27 US fl oz (0.74-0.80 L)
Length:
Approx. 90.4 in (2296 mm)
Width:
Approx. 36.5 in (927 mm)
Height:
Approx. 48.2 in (1224 mm)
Wheelbase:
Approx. 60.4 in (1534 mm)
Ground Clearance:
Approx. 5.0 in (127 mm)
Dry Weight:
Approx. 576 lbs (261 kg)
Gross Vehicle Weight Rating:
Approx. 1000 lbs (454 kg)
Fuel Tank Capacity:
4.5 US gal (17.0 L)
Seat Height:
Approx. 26.0 in (660 mm) laden
Vehicle Type Approval:
Motorcycle (specific safety ratings like NHTSA or Euro NCAP do not typically apply to motorcycles in the same way as cars).
Braking System:
Hydraulic disc brakes front and rear. Front: Dual piston caliper with 292mm disc. Rear: Single piston caliper with 292mm disc.
Lighting:
Halogen headlight, LED tail light, incandescent front and rear turn signals.
Chassis Design:
Steel frame and swingarm designed for stability and handling.
Instrumentation:
Analog speedometer, tachometer (optional or integrated into speedo on some models), fuel gauge, indicator lights for turn signals, oil pressure, high beam, and engine diagnostics.
Audio System:
No integrated audio system on base models. Aftermarket audio integration is common.
ABS:
Anti-lock Braking System (ABS) was often an optional feature for this model year. Manual will detail its operation and maintenance if equipped.
Diagnostic Port:
A diagnostic port is available for connecting diagnostic tools, likely using the HD-LAN interface.
First Service:
1,000 miles (1,600 km) or 6 months, whichever comes first. Includes engine oil and filter change, primary chain adjustment, and general inspection.
Subsequent Oil Change:
Every 5,000 miles (8,000 km) or 12 months, whichever comes first. Includes engine oil and filter change.
Primary Fluid Change:
Recommended every 10,000 miles (16,000 km) or 24 months.
Brake Fluid Flush Replace:
Every 2 years or as needed, based on inspection and performance.
Belt Tension Check Adjust:
Every 5,000 miles (8,000 km).
Engine Oil Viscosity:
20W50
Fork Oil Type:
Harley-Davidson Type E or equivalent 10W fork oil (check manual for specific quantity per leg).
Common Wear Items:
Clutch plates, brake pads, drive belt, fork seals, and wheel bearings are typical wear items requiring periodic inspection and replacement.
Electrical Connections:
Corrosion or loosening of electrical connectors can cause intermittent issues. Regular inspection and dielectric grease application are recommended.
Fuel System Maintenance:
Regular use of quality fuel and occasional fuel system cleaner can prevent injector clogging.
Harley Davidson Legacy:
Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer known for its V-twin engines and custom culture.
Sportster Lineage:
The Sportster line dates back to 1957, evolving from its earlier K-model predecessors. The 1200cc Evolution engine has been a staple since the 1980s, continuously refined.
Manufacturing Location:
United States (typically Milwaukee, Wisconsin, or York, Pennsylvania)
Model Year Introduction:
The XL 1200C Custom variant was introduced to cater to a demand for chrome and classic styling within the Sportster lineup.
Model Awards:
While specific awards for the 2008 XL 1200C are not widely documented, the Sportster line has consistently been recognized for its style, customization potential, and enduring appeal within the cruiser segment.
Editor Reviews Historical:
Motorcycle publications of the era often praised the 1200 Custom for its strong V-twin torque, classic styling, and comfortable riding position for cruiser enthusiasts.